Reconfigurable Converting Line for Fabricating Absorbent Articles

ABSTRACT

The present disclosure relates to converting lines for manufacturing absorbent articles, and more particularly, to converting lines having modular process equipment modules and converting mechanisms reconfigurable for making different absorbent articles.

FIELD OF THE INVENTION

The present disclosure relates to converting lines for manufacturingabsorbent articles, and more particularly, to converting lines havingmodular process equipment modules and converting mechanismsreconfigurable for making different absorbent articles.

BACKGROUND OF THE INVENTION

Disposable, reusable and durable products such as diapers, adultincontinence articles, feminine hygiene tampons, sanitary napkins,underpants, shirts, shorts, swimsuits, gowns, pants, coats, gloves,scarves, surgical drapes, bibs, blankets, sheets, pillow cases, etc. maybe manufactured on high speed converting lines. A converting line mayutilize a web-based carrier to which many source materials, whether in acontinuous web or discrete pieces, are processed and/or attached to theweb to create a finished product.

Although a converting line may allow for high speed production, someconverting lines may be inflexible in that line changes are timeconsuming and expensive. For example, some converting lines may requireextensive disassembly and reassembly when conducting maintenance and/orreplacing certain components. In another example, converting lines mayrequire substantial disassembly and rework in order to accommodateproduct upgrades. In one scenario, a product upgrade may, for example,require the following steps: constructing manual or handmade productsincorporating the upgrade in order to test the concept and determineconsumer acceptance of such an upgrade; constructing a machineproduction unit that may manufacture the product upgrade and/or theentire product incorporating the upgrade in order to determine productand process feasibility; constructing a high speed test stand that maymanufacture the product upgrade in isolation at high speeds in order totest the feasibility of high speed manufacturing; constructing aprototype line that is able to make complete prototype products at highspeeds; reconstructing a high speed production line to implement theprocess changes necessary for the product upgrade; and testing anddebugging the production line. In yet another example, converting linesare inflexible to make more than one type of product. In one scenario,in order to make a different product on an existing line, the followsteps are required: portions of the line must be disassembled;reassembled of the line in the new configuration; testing to qualify theline in the new configuration. The aforementioned efforts may beexpensive and time consuming, especially when the reconstruction,testing and debugging steps lead to down time of a high speed productionline. Further, when a product upgrade is rolled out on multipleproduction lines, the time and money required to implement even a smallchange in each individual line may increase dramatically. Often, thetime and money required will be prohibitive, and highly desirableproduct upgrades may be delayed or even eliminated.

In an attempt to facilitate faster installation, servicing, andadjustment of the working devices, some converting lines may includemodular sections joined together. However, such converting lines do notaccount for difficulties in shipping and require modules to plug intomezzanine type accessory ducts permanently installed. Thus, a convertingline configuration that allows for relatively fast and easy productdevelopment, relatively low cost and efficient shipping, andreconfiguration is desired, which also minimizes down time due totesting and debugging a production converting line after construction orreconstruction.

SUMMARY OF THE INVENTION

The present disclosure relates to converting lines for manufacturingabsorbent articles, and more particularly, to converting lines havingmodular process equipment modules and converting mechanismsreconfigurable for making different absorbent articles.

In one form, an apparatus for the fabrication of disposable absorbentarticles includes: a first converting module, a second convertingmodule, and a third converting module, each converting module includinga first wall and a second wall separated by a base and a top anddefining an interior space, and wherein the each converting moduledefines a MD length, a CD width, and a height; a first accessory servicemodule, a second accessory service module, and a third accessory servicemodule, each accessory service module comprising at least one utilityduct selected from the group consisting of: a compressed air headerduct, a vacuum air header duct, and an electrical power distribution busduct, and wherein each accessory service module defines a MD lengthequal to or less than the MD length of each of the converting modules; afirst absorbent article converting mechanism disposed in the interiorspace of the first converting module, the first absorbent articleconverting mechanism releasably connectable with the at least oneutility duct of the first accessory service module; a second absorbentarticle converting mechanism disposed in the interior space of thesecond converting module, the second absorbent article convertingmechanism releasably connectable with the at least one utility duct ofthe second accessory service module; a third absorbent articleconverting mechanism disposed in the interior space of the thirdconverting module, the third absorbent article converting mechanismreleasably connectable with the at least one utility duct of the thirdaccessory service module; wherein in a first configuration, the secondconverting module is disposed between the first converting module andthe third converting module along an MD direction, and the secondaccessory service module is disposed between the first accessory servicemodule and the third accessory service module along the MD direction,such that combination of the first, second, and third absorbent articleconverting mechanisms are adapted to produce a first absorbent article;and wherein in a second configuration, the second converting module isremoved, and the first converting module is connected directly with thethird converting module, and the second accessory manifold is removed,and the first accessory manifold is connected directly with the thirdaccessory manifold, such that combination of the first and thirdabsorbent article converting mechanisms are adapted to produce a secondabsorbent article different from the first absorbent article.

In another form, a reconfigurable converting line for the fabrication ofdisposable absorbent articles includes: a first converting module, asecond converting module, a third converting module, and a fourthconverting module, each converting module defining an interior space,and wherein the each converting module defines a MD length, a CD width,and a height and wherein the MD lengths of each converting module aresubstantially the same; a first accessory service module, a secondaccessory service module, and a third accessory service module, eachaccessory service module comprising at least one utility duct selectedfrom the group consisting of: a compressed air header duct, a vacuum airheader duct, and an electrical power distribution bus duct, and whereineach accessory service module defines a MD length equal to or less thanthe MD length of each of the converting modules; a first absorbentarticle converting mechanism disposed in the interior space of the firstconverting module, the first absorbent article converting mechanismreleasably connectable with the at least one utility duct of the firstaccessory service module; a second absorbent article convertingmechanism disposed in the interior space of the second module, thesecond absorbent article converting mechanism releasably connectablewith the at least one utility duct of the second accessory servicemodule; a third absorbent article converting mechanism disposed in theinterior space of the third module, the third absorbent articleconverting mechanism releasably connectable with the at least oneutility duct of the third accessory service module; a fourth absorbentarticle converting mechanism disposed in the interior space of thefourth module, the fourth absorbent article converting mechanismreleasably connectable with the at least one utility duct of the secondaccessory service module; wherein in a first configuration, the secondconverting module is disposed between the first converting module andthe third converting module along an MD direction, and the secondaccessory manifold is disposed between the first accessory manifold andthe third accessory manifold along the MD direction, such thatcombination of the first, second, and third absorbent article convertingmechanisms are adapted to produce a first absorbent article; and whereinin a second configuration, the fourth converting module is disposedbetween the first converting module and the third converting modulealong an MD direction, and the second accessory manifold is disposedbetween the first accessory manifold and the third accessory manifoldalong the MD direction, such that combination of the first, fourth, andthird absorbent article converting mechanisms are adapted to produce asecond absorbent article different from the first absorbent article.

In yet another form, a method for changing a converting line from afirst configuration for fabricating first disposable absorbent articlesto a second configuration for fabricating second disposable asorbentarticles different from the first absorbent articles includes the stepsof: providing a first converting module, a second converting module, anda third converting module, and wherein each converting module defines aMD length, a CD width, and a height, the second converting modulereleasably connected with and between the first converting module andthe third converting module; providing a first accessory service modulesupported by the first converting module, a second accessory modulesupported by the second converting module, and a third accessory modulesupported by the third converting module; providing a first absorbentarticle converting mechanism supported by the first converting module, asecond absorbent article converting mechanism supported by the secondconverting module, and a third absorbent article converting mechanismsupported by the third converting module; disconnecting the secondconverting module from the first converting module and the thirdconverting module; removing the second converting module and the secondabsorbent article converting mechanism from between the first convertingmodule and the third converting module; and supporting the secondaccessory service module from the first accessory service module and thethird accessory service module.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of an embodiment of a convertingline.

FIG. 2 is a front side view of the converting line of FIG. 1 showingschematic representations of converting mechanisms housed within theconverting modules.

FIG. 3 is a detailed perspective view of a converting module andassociated accessory service modules from the converting line of FIG. 1.

FIG. 4 is a right side view of the converting module and accessoryservice modules of FIG. 3.

FIG. 5 is an exploded view of a converting module coupler arranged toconnect two converting modules together.

FIG. 6 is a detailed exploded perspective view of a converting modulecoupler shown in FIG. 5.

FIG. 7 is a detailed assembly view of the converting module coupler ofFIG. 6.

FIG. 8 is a perspective view of a converting module.

FIG. 9 is a perspective view of a first accessory service module.

FIG. 10 is a perspective view of a second accessory service module.

FIG. 11 is a detailed perspective view of three converting modules andaccessory service modules from FIG. 1.

FIG. 12 is a detailed perspective view showing the middle convertermodule removed from the arrangement shown in FIG. 11.

FIG. 13 is a detailed perspective view showing middle accessory servicemodules removed from the arrangement shown FIG. 11.

FIG. 14 is a detailed perspective view showing the middle convertermodule and associated accessory service modules removed from thearrangement shown FIG. 11.

FIG. 15 is a front side view of the three converting modules and havinga folding converting mechanism in the second converting module.

FIG. 16 is a detailed perspective view of three converting moduleswherein the second converting module of FIG. 15 is replaced with asecond converting module having a patch cut and slip convertingmechanism.

FIG. 17 is a front side view of the converting modules of FIG. 16.

FIG. 18 is a detailed perspective view of three converting moduleswherein the second converting module of FIG. 15 is replaced with asecond converting module having an ultrasonic treatment convertingmechanism.

FIG. 19 is a front side view of the converting modules of FIG. 18.

FIG. 20 is a detailed perspective of two converting modules wherein thesecond converting module and associated accessory service module fromFIG. 15 has been removed and the first and third converting modules areconnected.

FIG. 21 is a front side view of the converting modules of FIG. 20.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. “Diaper” isused herein to refer to an absorbent article generally worn by infantsand incontinent persons about the lower torso. The term “disposable” isused herein to describe absorbent articles which generally are notintended to be laundered or otherwise restored or reused as an absorbentarticle (e.g., they are intended to be discarded after a single use andmay also be configured to be recycled, composted or otherwise disposedof in an environmentally compatible manner).

The term “disposed” is used herein to mean that an element(s) is formed(joined and positioned) in a particular place or position as amacro-unitary structure with other elements or as a separate elementjoined to another element.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a layer or layers or fibrousmaterials, films and foils such as plastic films or metallic foils thatmay be used alone or laminated to one or more web, layer, film and/orfoil. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, and the like.Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. The term “cross direction”(CD) is used herein to refer to a direction that is generallyperpendicular to the machine direction.

The present disclosure relates to converting lines for manufacturingabsorbent articles. An absorbent article converting line may include acombination of converting mechanisms that move substrates and componentmaterials through a manufacturing process. While advancing in themachine direction MD through the converting line, substrates may becombined with the other substrates and/or discrete components to createa continuous length of absorbent articles. Various substrates can beused to construct various components of the absorbent articles, such asbacksheets, topsheets, and absorbent cores. Exemplary descriptions ofabsorbent article components are provided in U.S. Pat. Nos. 3,860,003;5,151,092; 5,554,145; 5,569,234; 5,580,411; and 6,004,306, which are allincorporated by reference herein. At a downstream portion of theconverting process, the continuous length of absorbent articles may besubjected to a final knife and cut to create separate and discreteabsorbent articles. In addition, defective articles may be removed fromthe process by a rejection system. Articles that are not deemed to bedefective may be subject to further processing steps, such as foldingand packaging.

The converting lines herein each include a plurality of processequipment converting modules connected with each other along a machinedirection (MD). Each converting module defines an interior space and mayhouse an absorbent article converting mechanism therein. Adjacentconverting modules may be releasably connectable to each other withconverting module couplers. The converting modules may also havesubstantially identical dimensions, wherein each converting moduledefines the same or substantially the same MD length, CD width, andheight. In addition to the aforementioned converting modules, theconverting line also includes a plurality of accessory service modulessupported by respective converting modules and connected with each otheralong the machine directions. The accessory service modules may includevarious ducts and provide access to service utilities, such aselectricity, vacuum, and compressed air, to the converting mechanisms.As discussed below, the accessory service modules may also define MDlengths that are the same or substantially the same as the MD lengths ofthe converting service ducts, and as such, may also be adapted to bereceived within standard shipping containers. Adjacent accessory servicemodules may be releasably connected to each other with accessory modulecouplers, which may include quick-disconnect couplers.

Although the present disclosure is provided in the context ofmanufacturing absorbent articles, and diapers in particular, it is to beappreciated that the systems and methods disclosed herein may be appliedto converting lines used to manufacture of various types of articles andproducts. Examples of other products include absorbent articles forinanimate surfaces such as consumer products whose primary function isto absorb and retain soils and wastes that may be solid or liquid andwhich are removed from inanimate surfaces such as floors, objects,furniture and the like. Non-limiting examples of absorbent articles forinanimate surfaces include dusting sheets such as the SWIFFER cleaningsheets, pre-moistened wipes or pads such as the SWIFFER WETpre-moistened cloths, paper towels such as the BOUNTY paper towels,dryer sheets such as the BOUNCE dryer sheets and dry-cleaning clothessuch as the DRYEL cleaning clothes all sold by The Procter & GambleCompany. Additional examples of products include absorbent articles foranimate surfaces whose primary function is to absorb and contain bodyexudates and, more specifically, devices which are placed against or inproximity to the body of the user to absorb and contain the variousexudates discharged from the body. Non-limiting examples of incontinentabsorbent articles include diapers such as PAMPERS diapers, training andpull-on pants such as PAMPERS FEEL 'N LEARN and EASY UPS, adultincontinence briefs and undergarments such as ATTENDS adult incontinencegarments, feminine hygiene garments such as panty liners, absorbentinserts, and the like such as ALWAYS and TAMPAX, toilet paper such asCHARMIN toilet paper, tissue paper such as PUFFS tissue paper, facialwipes or clothes such as OLAY DAILY FACIAL wipes or clothes, toilettraining wipes such as KANDOO pre-moistened wipes, all sold by TheProcter & Gamble Company. Still other examples of products includepackaging components and substrates and/or containers for laundrydetergent and coffee, which may be produced in pellets or pouches andmay be manufactured in a converting or web process or even discreetproducts produced at high speed such as high-speed bottling lines,cosmetics, razor blade cartridges, and disposable consumer batteries.

FIGS. 1 and 2 show an embodiment of a converting line 100 including aplurality of process equipment converting modules 101 arranged along amachine direction MD. As shown, seven converting modules 101 arepositioned on a floor with an additional converting module 101 stackedon top of another. Although the converting line 100 includes eightconverting modules 101, it is to be appreciated that other embodimentsmay include more or less than eight converting modules. As discussed inmore detail below, the converting modules 101 are releasably connectedto each other and may be configured with substantially the samedimensional features. The converting modules 101 may also house and/orsupport a converting mechanism 102. The converting mechanisms 102 may beconfigured to perform various different manufacturing functions alongthe converting line 100. The converting line shown in FIGS. 1 and 2 alsoincludes a plurality of accessory service modules 103 arranged along themachine direction. The accessory service modules 103 provide access tovarious utilities to the converting modules 101 and/or convertingmechanisms 102 and are releasably connected with each other. Asdiscussed below, the accessory service modules 103 are supported bycorresponding converting modules 101 and/or by adjacent accessoryservice modules 103.

FIGS. 3 and 4 show an embodiment of a converting module 101 supportingtwo accessory service modules 103, and FIG. 8 shows the convertingmodule 101 with the accessory service modules 103 removed. As shown, theconverting module 101 may include a converting cabinet 104 and acontroller cabinet 106. The converting cabinet supports a firstaccessory service module 103 a, and the controller cabinet 106 supportsa second accessory service module 103 b. A cable tray 108 connects theconverting cabinet 104 with the controller cabinet 106. As discussed inmore detail below, the cable tray 108 may also function as a walkway 110and may be selectively configurable to reduce the CD width of theconverting module 101.

With reference to FIGS. 3, 4, and 8, the converting cabinet 106 includesa top 112 and a base 114 separated by a first wall 116 and a second wall118. An interior space 120 is defined by between the first wall 116, thesecond wall 118, the top 112, and the base 114. As discussed in moredetail below, a converting mechanism 102 may be disposed in the interiorspace 120. Portions of the converting mechanism 102 may be supported bythe second wall 118 and/or the base 114 of the converting cabinet 104.In addition, the first wall 116 may include doors having transparentpanels to enable access and viewing of the interior space 120 of theconverting cabinet 104. The controller cabinet 106 may include fourwalls 124 connected with and separating a base side 126 from a top side128. The controller cabinet 106 may be configured to house variousitems, such as motor control modules, which may in turn, be connectedwith the converting mechanism 102 with cables. Such cables may be routedfrom the controller cabinet 106 to the converting cabinet 104 throughthe cable tray 108. The controller cabinet 106 may also include one ormore doors 130 to provide access to the items housed within thecontroller cabinet 106.

As shown in FIG. 8, the converting module defines a MD length 132, a CDwidth 134, and a maximum height 136. With the converting module 101embodiment shown in FIG. 8, the height of the controller cabinet 106 isgreater than the height of the converting cabinet 104, and thus, thecontroller cabinet 106 defines the maximum height 136 of the convertingmodule 101. It is to be appreciated that in other embodiments, theheight of the converting cabinet 104 may be the same or greater than theheight of the controller cabinet 106. It should also be appreciated thatthe converting modules 101 may be configured to have various ranges ofMD lengths, CD widths, and heights. For example, in one embodiment, theconverting line 100 may include converting modules 101 having MD lengths132 of less than or equal to 2200 mm, CD widths 134 of less than orequal to 3570 mm, and/or heights 136 of less than or equal to 2275 mm.

As previously mentioned, the converting modules 101 may be releasablyconnected with adjacent converting modules 101 along the machinedirection MD. For example, FIG. 5 shows a converting module coupler 138for releasably connecting two converting modules 101 with each other.FIGS. 6 and 7 show detailed views of one embodiment of the convertingmodule coupler 138. With reference to FIGS. 5-7, when connecting twoconverting modules 101 together, one converting module 101 is placeadjacent to another converting module 101 with a space or gap betweenthe converting modules along the MD direction. In one embodiment, thespace may be 20 mm. A spacer or a set of complimentary wedges 140, 142,144 may be inserted between the converting modules 101 in the MD gap orspace provided. A pin 146 and two bolts 148 may be inserted throughholes 150 in the spacer or wedges 140, 142, 144 and corresponding holesin the adjacent converting modules 101. The bolts 148 may be joined withnuts 152 to provide a tight connection between the converting modules101. It is to be appreciated that one, two, three, or four sets ofspacers or wedges with pins and bolts can be used to releasably connectthe converting modules 101 to provide a desired spacing, alignment, andconnection. It is also to be appreciated that other types of convertingmodule couplers 138 may be used to provide for connection and alignmentas well as releasably connect the converting modules 101 together.

As previously mentioned, the converting modules 101 may house varioustypes of converting mechanisms 102. For example, the configuration shownin FIGS. 1 and 2 illustrates a converting line 100 including eightconverting modules 101 housing eight corresponding converting mechanisms102, which in combination, are adapted to produce a disposable absorbentarticle in the form of a diaper. Each converting mechanism 102 may beconfigured to perform various functions of the converting process asmaterials advance in the machine direction MD through the convertingline 100. The following provides a general description of variousconverting mechanism arrangements that may be utilized with theconverting line 100.

With reference to FIGS. 1 and 2, in one embodiment, the converting linemay 100 include a first converting module 1001 housing a firstconverting mechanism 1002 in the converting cabinet 104. The firstconverting mechanism 1002 may be adapted to create a composite web byforming an absorbent patch and combining the absorbent patch with atopsheet carrier web and a second absorbent patch. The composite web maythen advance in the machine direction to a second converting mechanism2002 housed within a second converting module 2001. The secondconverting module 2001 is releasably connected with the first convertingmodule 1001. The second converting mechanism 2002 may be adapted to folda topsheet carrier web around absorbent materials and to add anadditional continuous web into the converting process. The composite webmay then advance in the machine direction to a third convertingmechanism housed within a third converting module 3001. The thirdconverting module 3001 is releasably connected with the secondconverting module 2001. The third converting mechanism 3002 may beadapted to periodically add a discontinuous thin material onto the web.The composite web may then advance in the machine direction to a fourthconverting mechanism 4002 housed within a fourth converting module 4001.The fourth converting module 4001 is releasably connected with the thirdconverting module 3001. The fourth converting mechanism 4002 may beadapted to compress the composite web. The composite web may thenadvance in the machine direction to a fifth converting mechanism 5002housed within a fifth converting module 5001. The fifth convertingmodule 5001 is releasably connected with the fourth converting module4001. The fifth converting mechanism 5002 may be adapted to transportthe composite web through the fifth converting module 5001. Thecomposite web may then advance in the machine direction to a sixthconverting mechanism 6002 housed within a sixth converting module 6001.The sixth converting module 6001 is releasably connected with the fifthconverting module 5001. The sixth converting mechanism 6002 may beadapted to ultrasonically treat the composite web. The composite web maythen advance in the machine direction to other converting modules 101housing other mechanisms and/or to other machinery which may furthertransform the web or package the assembled products.

The converting line in FIGS. 1 and 2 also includes a seventh convertingmodule 7001 disposed on top of the first converting module 1001. Theseventh converting module 7001 may include a seventh convertingmechanism 7002 adapted to meter and deliver two forms of particulateabsorbent material to the first converting module 1001 from which theabsorbent patches are formed. Further, the seventh module 7001 may alsosupport equipment which supplies vacuum to the fluid services header. Inaddition, the converting line 100 may includes an eighth module 8001positioned adjacent to and upstream of the first converting module 1001.The eighth module 8001 may include a converting mechanism 8002 adaptedto supply a topsheet carrier web to the first converting module 101 andalso supply continuous absorbent material to the seventh module 7001 fordisintegration into particulate absorbent material.

As discussed above, the converting line 100 includes a plurality ofaccessory service modules 103 supported by respective converting modules101. The accessory service modules 103 provide service utilities to theconverting modules 101 and/or converting mechanisms 102 housed withinthe converting modules. It is to be appreciated that the accessoryservice modules 103 may include more or less and/or different serviceutilities than are shown and described herein.

For example, FIG. 9 shows a first embodiment of an accessory servicemodule 103 a that includes a plurality of accessory service ducts 154,such as for example, a compressed air header duct 156 and a vacuum airheader duct 158. The accessory service modules 103 may be supported bycorresponding converting modules 101 in various ways. For example, theaccessory service module 103 a shown in FIG. 9 includes support brackets160 that can be releasably connected with a corresponding convertingmodule 101. For example, the support brackets 160 shown in FIG. 9 areadapted to connect with the top 112 of a converting cabinet 104, such asshown in FIG. 3. It is to be appreciated that the support brackets canbe releasably connected with the converting modules in various ways,such as for example, nuts 162 and bolts 164 or other types of fasteners.The support brackets 160 are also configured to support the accessoryservice ducts 154 above the top of the converting cabinet 104. Theaccessory service module 103 may also include duct couplers 166releasably connecting accessory service ducts 154 with adjacentconverting modules 101 and/or converting mechanisms 102 housed therein.It is to be appreciated that duct couplers 166 may be configured invarious ways. For example, as shown in FIG. 9, the duct couplers 166 mayinclude rigid pipes 168 and/or flexible hoses 170 as well as releasableconnectors 172 such as unions and/or other types of pipe or hose quickdisconnects.

A second embodiment of an accessory service module 103 b is shown inFIG. 10 that includes an accessory service duct 154 housing anelectrical power distribution bus duct 174. The accessory service module103 b shown in FIG. 10 also includes support brackets that can beconnected with a corresponding converting module 101. For example, thesupport brackets 160 shown in FIG. 10 are adapted to connect with thetop 128 of a controller cabinet 106, such as shown in FIG. 3. Thesupport brackets 160 can also be releasably connected with theconverting modules 101 in various ways, such as for example, nuts 162and bolts 164 or other types of fasteners. The support brackets 160 arealso configured to support the accessory service ducts 154 above the top128 of the controller cabinet 106. As mentioned above, the accessoryservice modules 103 may also include various forms of duct couplers 166to releasably connect accessory service ducts 154 with adjacentconverting modules 101 and/or converting mechanisms 102 housed therein.For example, as shown in FIG. 10, the duct couplers 166 may include ajunction box 176 and associated rigid and/or flexible conduits 178 aswell as releasable connectors 172 such as unions and/or other types ofpipe or hose quick disconnects to releasably connect the electrical busducts 174 with adjacent converting modules 101. Cables may alsoreleasably connect the electrical power distribution bus ducts withservo motor controller housed within respective controller cabinets.

As discussed above, a plurality of accessory service modules 103 arearranged along the machine direction MD and may be supported byrespective converting modules 101. In addition, the accessory servicemodules 103 may be releasably connected with each other with accessoryservice module couplers 180. As discussed in more detail below, anaccessory service module 103 may be supported by adjacent accessoryservice modules 103 when a corresponding converting module 101 isremoved from the converting line 100. The accessory service modulecouplers 180 may comprise various forms of quick-disconnect couplers.For example, in one embodiment, the accessory service module couplers180 may be configured as flange pull ring locking collars 182, such asshown in FIG. 9, to releasably connect adjacent vacuum air header ducts158. In another example shown in FIG. 9, the accessory service modulecouplers 180 may be configured as push-lock couplers 184 which may be incombination with flexible piping 186 to connect adjacent compressed airducts 156. In other embodiments, the accessory service module couplers180 may comprise, sliding sleeve couplers, cam and groove lockingcouplers, and flexible pipe hose clamps. In another example, shown inFIG. 10, the accessory service module couplers 180 may includequick-disconnect plugs and bus splice joint plates 188, bus tap orplug-in boxes to releasably connect adjacent electrical powerdistribution bus ducts 174.

As mentioned above, the releasable connections between adjacentconverting modules 101 and accessory service modules 103 provideflexibility to the converting line 100 when removing, installing, and/orreplacing converting modules 101 and/or accessory service modules 103.An example of such flexibility is discussed in more detail below withregard to FIGS. 11-14. In particular, FIG. 11 shows a detailed view ofthree converting modules 101 and associated accessory service modules103 from the converting line 100 shown in FIG. 1. Specifically, FIG. 11shows the second converting module 2001 and associated accessory servicemodules 103 a, 103 b connected with and between the first convertingmodule 1001 and third converting module 3001 and respective accessoryservice modules 103, 103 a. And FIGS. 12-14 show various configurationsof the arrangement of FIG. 11 wherein the second converting module 2001and/or associated accessory service modules 103 are removed. With regardto FIGS. 11-14, the middle accessory service modules refers to theaccessory service modules 103 a, 103 b connect with the secondconverting module 2001.

On some occasions, such as during maintenance and/or installationactivities or disassembly, it may be necessary or desirable to removeand/or replace a converting module 101 from the converting line 100. Thereleasable connections between adjacent converting modules 101 andaccessory service modules 103 allows for the removal of a convertingmodule 101 without having to remove associated accessory service modules103. For example, as shown in FIG. 12, the second (middle) convertingmodule 2001 is removed while the middle accessory service modules 103 a,103 b remain connected with and supported between the accessory servicemodules 103 a, 103 b associated with and supported by the firstconverting module 1001 and the third converting module 3001. To removethe second converting module 2001 from FIG. 11 to arrive at theconfiguration shown in FIG. 12, the converting modules couplers 138,such as shown in FIGS. 5-7, may be disconnected and removed from betweenthe second converting module 2001 and the first and third convertingmodules 1001, 3001. In addition, the support brackets 160 and ductcouplers 166, such as shown in FIGS. 9 and 10 may be disconnected fromthe second converting module 2001. The second converting module 2001 maythen be moved in CD direction out from between the first convertingmodule 1001 and the third converting module 3001, leaving the middleaccessory service modules 103 a, 103 b supported by the accessoryservice modules 103 a, 103 b associated with the first and thirdconverting modules 1001, 3001. When desired, a second converting module2001 can be reinserted into the converting line 100, and reconnectedwith adjacent converting modules 1001, 3001 and accessory servicemodules 103 a, 103 b.

In some situations, it may be necessary or desirable to remove and/orreplace an accessory service module 103 from the converting line 100.The releasable connections between adjacent converting modules 101 andaccessory service modules 103 allow for the removal of an accessoryservice module 103 without having to remove associated convertingmodules 101. For example, as shown in FIG. 13, the middle accessoryservice modules 103 a, 103 b are removed while the second convertingmodule 2001 remains connected between the first and third convertingmodules 1001, 3001. To remove the middle accessory service module 103 a,103 b from FIG. 10 to arrive at the configuration shown in FIG. 13, theaccessory service module couplers 180, such as shown in FIGS. 9 and 10,may be disconnected and removed from between the middle accessoryservice modules 103 a, 103 b supported by the second converting module2001 and the accessory service modules 103 a, 103 b supported by thefirst and third converting modules 1001, 3001. In addition, the supportbrackets 160 and duct couplers 166, such as shown in FIGS. 9 and 10 maybe disconnected from the second converting module 2001. The middleaccessory service module may then be moved out from between theaccessory service modules 103 a, 1030 b supported by the first and thirdconverting modules 1001, 3001, leaving the second converting module 2001in place between the first and third accessory service modules 1001,3001. When desired, the middle accessory service modules 103 a, 103 bcan be reinserted into the converting line 100, and reconnected withadjacent converting modules and accessory service modules.

In yet other instances, it may be necessary to remove and/or replace anaccessory service module 103 and associated converting module 101 fromthe converting line. For example, as shown in FIG. 14, the middleaccessory converting modules 103 a, 103 b and second converting module2001 are removed, while the first and third converting modules 1001,3001 and associated accessory service modules 103 a, 103 b remaininstalled on the converting line. To remove the middle accessory servicemodules 103 a, 103 b and second converting module 2001 from FIG. 10 toarrive at the configuration shown in FIG. 14, the converting modulescouplers 138, such as shown in FIGS. 5-7, may be disconnected andremoved from between the second converting module 2001 and the first andthird converting modules 1001, 3001. In addition, the accessory servicemodule couplers 180, such as shown in FIGS. 9 and 10, may bedisconnected and removed from between the middle accessory servicemodules 103 a, 103 b and the adjacent accessory service modules 103 a,103 b. The middle accessory service modules 103 a, 103 b and secondconverting module 2001 may then be moved in CD direction out frombetween the first and third converting modules 1001, 3001 and associatedaccessory service modules 103 a, 103 b. Once removed from the convertingline 100, the middle accessory service modules 103 a, 103 b can bedisconnected from the second converting module 2001. In other variationsto the disassembly process above, the middle accessory convertingmodules may be removed from the converting line before removing thesecond converting module. In yet another variation, the secondconverting module may be removed from the converting line beforeremoving second accessory service modules. When desired, middleaccessory service modules 103 a, 103 b and converting module 2001 can bereinserted into the converting line and reconnected with adjacentconverting modules and accessory service modules.

The above discussion provides a basis for the following exampledescriptions of how the converting line can be reconfigured to producedifferent products by replacing converting modules with other convertingmodules and/or by removing converting modules from the converting line.

FIGS. 15 shows three example converting modules 101, convertingmechanisms 102, and associated accessory service modules 103 from aconverting line 100 arranged along the machine direction MD. Inparticular, FIG. 15 shows a first converting module 1001 a housing afirst converting mechanism 1002 a. The first converting mechanism 1002 amay be adapted to create a composite web by forming an absorbent patchand combining the absorbent patch with a topsheet carrier web and asecond absorbent patch. The composite web may then advance in themachine direction to a second converting mechanism 2002 a housed withina second converting module 2001 a. The second converting module 2001 ais releasably connected with the first converting module 1001 a. Thesecond converting mechanism 2002 a is adapted to fold the topsheetcarrier web around the absorbent materials and to add an additionalcontinuous web into the process. The composite web may then advance inthe machine direction MD from the second converting mechanism 2002 a toa third converting mechanism 3002 a housed within a third convertingmodule 3001 a. The third converting module 3001 a is releasablyconnected with the second converting module 2001 a. The third convertingmechanism 3002 a is adapted to compress the composite web. The compositeweb may then advance in the machine direction MD from the thirdconverting module 3001 a to other similar modules housing othermechanisms or to other machinery which may further transform the web orpackage the product. For the purposes of the present discussion, thecomposite web advancing from the third converting mechanism 3002 a inthe converting arrangement shown in FIG. 15 may be described as aportion of a first absorbent article with absorbent patches and atopsheet carrier web which is folded to encapsulating the absorbentpatches, and with a continuous backsheet web.

FIGS. 16 and 17 show a modified converting module arrangement of FIG. 15wherein the second converting module 2001 a and second convertingmechanism 2002 a has been removed and replaced with a different secondconverting module 2001 b and second converting mechanism 2002 b. Anexample of how converting modules and associated converting mechanismsmay be removed and replaced is described above with reference to FIGS.11 and 12. Referring back to FIGS. 16 and 17, the second convertingmodule 2001 b is releasably connected with the first and thirdconverting modules 1001 a, 3001 a. In addition, the second convertingmechanism 2002 b is adapted to periodically add a discontinuous thinmaterial onto the web received from the first converting module 1001 a.The composite web may then advance in the machine direction MD from thesecond converting module 2001 a to the third converting module 3001 aand third converting mechanism 3002 b. For the purposes of the presentdiscussion, the composite web advancing from the third convertingmechanism 3002 a in the converting arrangement shown in FIGS. 16 and 17may be described as a portion of a second absorbent article withabsorbent patches and a topsheet carrier web, and with a discrete patchof elasticized material applied between the absorbent patches.

In another example, FIGS. 18 and 19 show a modified converting modulearrangement of FIG. 15 wherein the second converting module 2001 a andsecond converting mechanism 2002 a has been removed and replaced with adifferent second converting module 2001 c and second convertingmechanism 2002 c. An example of how converting modules and associatedconverting mechanisms may be removed and replaced is described abovewith reference to FIGS. 11 and 12. Referring back to FIGS. 18 and 19,the second converting module 2001 c is releasably connected with thefirst and third converting modules 1001 a, 3001 a. In addition, thesecond converting mechanism 2002 c is adapted to adapted toultrasonically treat the composite web received from the firstconverting module 1001 a. The composite web may then advance in themachine direction MD from the second converting module 2001 c to thethird converting module 3001 a and third converting mechanism 3002 a.For the purposes of the present discussion, the composite web advancingfrom the third converting mechanism 3002 a in the converting arrangementshown in FIGS. 18 and 19 may be described as a portion of a thirdabsorbent article with absorbent patches and a topsheet carrier web, andwith the areas between the absorbent patches ultrasonically treated.

In yet another example, FIGS. 20 and 21 show a modified convertingmodule arrangement of FIG. 15 wherein the second converting module 2001a, second converting mechanism 2002 a, and associated accessory servicemodules 103 have been removed. And the either the first convertingmodule 1001 a and the third converting module 3001 a or both have beenmoved in the machine direction MD to be adjacent to each other. Anexample of how converting modules and associated converting mechanismsand accessory service modules may be removed is described above withreference to FIGS. 11-14. Referring back to FIGS. 20 and 21, the firstconverting module 1001 a is releasably connected directly with the thirdconverting module 3001 a. For the purposes of the present discussion,the composite web advancing from the third converting mechanism 3002 ain the converting arrangement shown in FIGS. 20 and 21 may be describedas a portion of a fourth absorbent article with absorbent patches and atopsheet carrier web.

The four converting arrangements described above with reference to FIGS.15-21 will each produce a different and unique composite web because thesecond converting module either different in each arrangement or hasbeen removed. One embodiment may be converted to another by exchangingone second module for another. For instance, the embodiment shown inFIG. 15 may be converted to the embodiment shown in FIGS. 16 and 17 byremoving folding module 201 from between the core forming module 101 andthe compression module 401 and replacing it with the cut & slip module301. The converting modules and their respective fluid and electricalservices modules are releasably connected such that one module may bedisconnected and removed and another module may be inserted andconnected without altering or disturbing the adjacent modules oraffecting the operability of the adjacent modules. Similarly theembodiment shown in FIG. 15 may be converted to that shown in FIGS. 18and 19 by removing folding module 201 from between the core formingmodule 101 and the compression module 401 and replacing it with theultrasonic module 601. As above the converting modules and theirrespective fluid and electrical services modules are releasablyconnected such that one module may be disconnected and removed andanother module may be inserted and connected without altering ordisturbing the adjacent modules or affecting the operability of theadjacent modules.

It is to be appreciated that the apparatuses and methods disclosedherein may be utilized with various different types and aspects ofmethods and apparatuses relating to converting lines, such as, forexample, described in the U.S. Patent Application identified by AttorneyDocket No. 11397, entitled “MODULAR CONVERTING LINE FOR FABRICATINGABSORBENT ARTICLES,” filed on Aug. 20, 2009; U.S. patent applicationidentified by Attorney Docket No. 11395, entitled “SYSTEMS AND METHODSFOR CONTINUOUS DELIVERY OF WEB MATERIALS,” filed on Aug. 20, 2009; U.S.patent application identified by Attorney Docket No. 11396, entitled“FLEXIBLE MANUFACTURING SYSTEMS AND METHODS,” filed on Aug. 20, 2009;and U.S. patent application identified by Attorney Docket No. 11398,entitled “SPEED CHANGE KIT FOR AN ABSORBENT ARTICLE CONVERTING LINE,”filed on Aug. 20, 2009, all of which are incorporated by referenceherein.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. An apparatus for the fabrication of disposable absorbent articlescomprising: a first converting module, a second converting module, and athird converting module, each converting module including a first walland a second wall separated by a base and a top and defining an interiorspace, and wherein the each converting module defines a MD length, a CDwidth, and a height; a first accessory service module, a secondaccessory service module, and a third accessory service module, eachaccessory service module comprising at least one utility duct selectedfrom the group consisting of: a compressed air header duct, a vacuum airheader duct, and an electrical power distribution bus duct, and whereineach accessory service module defines a MD length equal to or less thanthe MD length of each of the converting modules; a first absorbentarticle converting mechanism disposed in the interior space of the firstconverting module, the first absorbent article converting mechanismreleasably connectable with the at least one utility duct of the firstaccessory service module; a second absorbent article convertingmechanism disposed in the interior space of the second convertingmodule, the second absorbent article converting mechanism releasablyconnectable with the at least one utility duct of the second accessoryservice module; a third absorbent article converting mechanism disposedin the interior space of the third converting module, the thirdabsorbent article converting mechanism releasably connectable with theat least one utility duct of the third accessory service module; whereinin a first configuration, the second converting module is disposedbetween the first converting module and the third converting modulealong an MD direction, and the second accessory service module isdisposed between the first accessory service module and the thirdaccessory service module along the MD direction, such that combinationof the first, second, and third absorbent article converting mechanismsare adapted to produce a first absorbent article; and wherein in asecond configuration, the second converting module is removed, and thefirst converting module is connected directly with the third convertingmodule, and the second accessory manifold is removed, and the firstaccessory manifold is connected directly with the third accessorymanifold, such that combination of the first and third absorbent articleconverting mechanisms are adapted to produce a second absorbent articledifferent from the first absorbent article.
 2. The apparatus of claim 1,wherein the first absorbent article converting mechanism comprises atopsheet web delivery system, a first absorbent patch forming drumsystem, and a second absorbent patch forming drum system, and acomposite web delivery system; wherein the second absorbent articleconverting mechanism comprises a topsheet folding board system, and abacksheet continuous web delivery system, and a composite web deliverysystem; and the third absorbent article converting mechanism comprises abond roll mechanisms, and a composite web delivery system.
 3. Theapparatus of claim 1, wherein the first accessory service module issupported on the top of the first converting module, the secondaccessory service module is supported on the top of the secondconverting module, and the third accessory module is supported on thetop of the third converting module.
 4. The apparatus of claim 1, furthercomprising a plurality of converting module couplers, the convertingmodule couplers releasably connecting first converting module with thesecond converting module and releasably connecting the second convertingmodule with the third converting module.
 5. The apparatus of claim 1,further comprising a plurality of duct couplers, the duct couplersreleasably connecting the first absorbent article converting mechanismwith the at least one utility duct of the first accessory servicemodule, releasably connecting the second absorbent article convertingmechanism with the at least one utility duct of the second accessoryservice module, and releasably connecting the third absorbent articleconverting mechanism with the at least one utility duct of the thirdaccessory service module.
 6. The apparatus of claim 1, wherein the MDlength of each converting module is less than or equal to 2200 mm, theCD width of each converting module is less than or equal to 3570 mm, andthe height of each converting module is less than or equal to 2275 mm.7. The apparatus of claim 1, wherein the first converting modulecomprises: a converting cabinet; a controller cabinet; and a cable trayconnecting the converting cabinet with the controller cabinet.
 8. Theapparatus of claim 7, further comprising a fourth accessory servicemodule, and wherein the first accessory service module is releasablyconnected with the first converting cabinet and the fourth accessoryservice module is releasably connected with the controller cabinet. 9.The apparatus of claim 6, wherein the cable tray comprises a walkway.10. The apparatus of claim 1, further comprising a plurality ofaccessory service module couplers comprising at least onequick-disconnect coupler selected from the group consisting of:bus-splice joint plate, plugs, bus tap or plug-in boxes, flange pullring locking collars, push-lock couplers, sliding sleeve couplers, camand groove locking couplers, and flexible pipe hose clamps, theaccessory service module couplers releasably connecting the firstaccessory service module with second accessory service module andconnecting the second accessory service module with the third accessoryservice module.
 11. The apparatus of claim 1, wherein the MD lengths ofthe converting modules are equal to each other.
 12. A reconfigurableconverting line for the fabrication of disposable absorbent articles,the reconfigurable converting line comprising: a first convertingmodule, a second converting module, a third converting module, and afourth converting module, each converting module defining an interiorspace, and wherein the each converting module defines a MD length, a CDwidth, and a height and wherein the MD lengths of each converting moduleare substantially the same; a first accessory service module, a secondaccessory service module, and a third accessory service module, eachaccessory service module comprising at least one utility duct selectedfrom the group consisting of: a compressed air header duct, a vacuum airheader duct, and an electrical power distribution bus duct, and whereineach accessory service module defines a MD length equal to or less thanthe MD length of each of the converting modules; a first absorbentarticle converting mechanism disposed in the interior space of the firstconverting module, the first absorbent article converting mechanismreleasably connectable with the at least one utility duct of the firstaccessory service module; a second absorbent article convertingmechanism disposed in the interior space of the second module, thesecond absorbent article converting mechanism releasably connectablewith the at least one utility duct of the second accessory servicemodule; a third absorbent article converting mechanism disposed in theinterior space of the third module, the third absorbent articleconverting mechanism releasably connectable with the at least oneutility duct of the third accessory service module; a fourth absorbentarticle converting mechanism disposed in the interior space of thefourth module, the fourth absorbent article converting mechanismreleasably connectable with the at least one utility duct of the secondaccessory service module; wherein in a first configuration, the secondconverting module is disposed between the first converting module andthe third converting module along an MD direction, and the secondaccessory manifold is disposed between the first accessory manifold andthe third accessory manifold along the MD direction, such thatcombination of the first, second, and third absorbent article convertingmechanisms are adapted to produce a first absorbent article; and whereinin a second configuration, the fourth converting module is disposedbetween the first converting module and the third converting modulealong an MD direction, and the second accessory manifold is disposedbetween the first accessory manifold and the third accessory manifoldalong the MD direction, such that combination of the first, fourth, andthird absorbent article converting mechanisms are adapted to produce asecond absorbent article different from the first absorbent article. 13.The apparatus of claim 12, wherein the first converting mechanismcomprises a topsheet web delivery system, a first absorbent patchforming drum system, and a second absorbent patch forming drum system,and a composite web delivery system; wherein the second absorbentarticle converting mechanism comprises a topsheet folding board system,and a backsheet continuous web delivery system, and a composite webdelivery system; and the third absorbent article converting mechanismcomprises a bond roll mechanisms, and a composite web delivery system;and the fourth converting mechanism comprises a elasticized materialdelivery system, and discrete patch forming and application mechanism,and a composite web delivery system.
 14. The apparatus of claim 12,wherein the first converting module comprises: a converting cabinet; acontroller cabinet; and a cable tray connecting the converting cabinetwith the controller cabinet. 15-20. (canceled)